Apparatus for conducting reactions in the presence of a contact mass



1948- 1 E. UTTERBACK ETAL 98 APPARATUS FOR CONDUCTING REACTIONS IN THEPRESENCE OF A CONTACT MASS 4 2 Sheets-Sheet 1 Filed July 29, 1943 IN VEN TOR;

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7 Dec. 21, 1948. I E. UTTERBACK ETAL 51,

APPARATUS FOR CONDUCTING REACTIONS IN THE PRESENCE OF A CONTACT MASS 2Sheets-Sheet 2 Filed July 29 T943 I J80 4Ctowggy k.

INVENTORJ j 7 ATTORNE Patented Dec. 21, 1948 UNITED STATES *PATENTOFFICE APPARATUS FOR CON DUCTING REACTIONS IN THE PRESENCE OF A CONTACTMASS Application July 29, 1943, Serial No. 496,648

' 6 Claims.

This invention has to do with apparatus for conducting reactions offluid reactants such as hydrocarbon vapors in the presence of a movingbed of particle form solid contact mass material which may or may not becatalytic to the desired reaction. Exemplary of the processes of thiskind is the cracking conversion of hydrocarbons, it being well knownthat hydrocarbons of a'gas oil nature boiling between about 500 F. andabout 750 F. may be substantially cracked to gasoline and lower boilinghydrocarbons by passing them at reaction conditions of temperature andpressure such as for example, temperatures of the order of 825 F. andabove at pressures somewhat above atmospheric in contact with a solidadsorptive catalytic contact mass. Usually such contact masses partakeof the nature of fullers earth, or other natural or treated filteringclays and/or various synthetic associations of alumina, silica, oralumina and silica, any of which may or may not have other constituentsadded for a purpose in connection with the processes such as certainmetallic oxides. In a most recentform this operation has been developedas one in which the particle for-m contact mass material is movedcyclically through two zones in the first of which it serves as acatalytic material for the reaction of concurrent or countercurrentflowing reactant fluids and in the second of which it is subjected tothe action of concurrent or countercurrent flowing fluid regeneratingmediums, such as a combustion supporting gas, acting to burn offcontaminant materials deposited upon thecontact mass in the reactionzone.

This invention has specifically to do with details of construction inconnection with reactors and regenerators wherein fluid reactants arebrought into contact with and subsequently separated from a movingstream of particle form. solid contact mass material. Inasmuch as thefunction and operation of this invention is the same in reactors orregenerators, the term reactor will hereinafter in the explanation ofthe invention and in claiming the invention be used in .a sensesufi'lciently broad to include fluid-solid contact apparatus regardlessof exact purpose of use.

It is general practice in such a cyclic reactorregenerator system asabove described to continuously and cyclically circulate therethrough aparticle form contact material of a specified range of particle sizes inwhich material'may be small percentages of undersized contact particleswhich are either continuously or periodically removed from the contactmaterial at somespecified part of the system. It is generallyundesirable to permit the carryover with the eiiluent reactant vaporsfrom either the reactor or regenerator vessels of any appreciablequantities of normal or undersized contact material, as such carryoverwould necessitate additional dust separation apparatus and/orcontaminate the condensed reaction products.

It is a major object of this invention to provide a means within reactoror regenerator vessels, such as described above, for the separation ofreactant vapors or spent combustion gases from the contact materialtherein and the continuous removal of said vapors or gases from thereactor or regenerator vessels without appreciable entrainment orcarryover in the vapor streams of particles of the contact material. Theinvention is specifically directed to details of construction andapplication of certain vapor flow distribution bafiles or plates to beused in the vaporcontact material disengaging section of reactor orregenerator vessels.

In order to readily understand this invention reference is made to thedrawings attached hereto in which Figure 1 shows a plan view of such adistribution plate and Figure 2 is a sectional elevation View showingthe application and arrangement of the bafile in the vapor outletsection of a reactor. Figure 3 is a plan view of a modified form of avapor distribution plate. Figure 4 is a plan view, partially in section,showing the use of a branched pipe manifold which involves the sameprinciple of design and purpose as the distribution plate; and Figure 5is an elevation View, partially in section showing the installation ofthe above manifold in a regenerator vapor outlet section. Figure 6 is asectional elevation view showing the use of specially arranged platebaffles which again involve the same principles of design and purpose asthe distribution plate. Figures 7 and 8 show two different kinds ofreactors and how the vapor flow distribution baflie would work in each.All of these drawings are diagrammatic in character.

Turning now to Figure 2, we find that I5 is the shell of a reactor usedto confine a downwardly flowing stream of solid particle form contactmaterial charged through pipe H. The reactor here shown is packed withsuperimposed rows of inverted angle shaped baiiles 25 interconnected byports in the tops of the angles. The top row of these angles connectsinto channels 24 to the top of which are connected vapor jumper pipes23. Thus a continuous shielded vapor passage is formed for the reactantvapors from the reaction zone up into the void disengaging space 30,through which passage the major portion of the reactant vapors may flowwithout having to bubble through the surface of the bed It of downwardl;flowing contact material. Near the top of the rea'ctorandato oppositesides ,are connected the two vapor outlet pipes 2i and 22. Just belowthese outlet pipes is the plate it which extends across the entire crosssection of the re.- actor and which is supportedsby ,rneans of-tansupports, 19 connected to the reactor ishell. "The contact material feedpipe l! extends'through the center of this plate, and in theremainderv'of the area are drilled a number of holesof such-a number andsize and so uniformlyfdistributed{that the total area of the holesingiven sectionpf the plate is proportioned to the area of reactor crosssection covered by that sectionHof-itheplate. in Figure l we find asectional plan view of theabove plate l8 supported by braces l9.Uniformly spaced about the plate cross section are the holes 20.Although anumber of circularholeszli are shown drilled-in the plate,holes or slots of other shape and holesvarying in size-would-serveequally well in accomplishing their function provided they are uniformlydistributed 'and proportioned to the reactor cross section controlledibythem and provided their total area is within'the proper limitsjwhich arespecifiedjhereinafter, For exampIe in "Figure-3 we find a sectional planview of such a distribution plate 18 extending across a-reactor 45, inwhich plate are drilled large diameter uniformly distributed round"holes through the center of each'of which extends a reactor contactmaterial feed'pipe ll of an outside diameter somewhat less than that ofthe hdles. Thus there remains a number of uniformly distributed annularspaces '25 in the' plate through which the effluent reactant vapors mustpass.

"Turning again to Figure 2 for a study of the function and operation ofthis invention, the major part of the vapors from the reaction zoneofthe reactor "pass up through 'the'ports in't he angles 25 to'thechannels" '26 and then up through the'jumper pipeslZZ-l into the voidspace 30. That fraction of the 'vaporsnot reaching the void space 3!!'viathis route leach itby passing directly up through the surface .ofthe contact materialgbed 16. Both of 'these'vaporstreams tend to'entrain and carry along some of the particle up therethrough calculated.on the space cross 5 section to1be below thatreguired to'fioat orcarrythe smallest particles of contact material the entrainment vof which itis desired tqprevent, and if the distance between the tgps .of ,thejumper pipes .23 and the vapor outlets 2! and 22 is'ade'quate, :mostofthe entrained contact material will settle to the top of the'bed I6.The e erm na o .of h d mension of the void disengaging space 30isydepen'dent upon amurnber of variables whichgneedinotbe discussedherein, and the "said dimensions are best determined experimentally. It3.11 be said, however, that in "a'llfthe applications for this invention'the'disengaging space usedis tobe considered as so designed as "to'bewithin the above broadly seated i specifications. -Since-the linearvelocity of vapor flow-up through-thedisengagingspace 30' is equal.

mane quotient of thetotalvolume of vapor flowing per unit of time upfrom I the *jumper pipes 23 "and the contactmaterial"bed' i6 divided by.pipes.or bed toward .the one, two or more outlet .pipesrsuchvas il :and22 on the periphery or sides of the vessel. Thus instead of uniformvapor fiowuputhroughethe disengaging space 38, high and low velocityzones of flow result, the condition:beco ningmore aggravated as theoutlet .l zil .cs"2,.-l and .22 are approached; and the vapor velocityin said high velocity zones is sufficient .to 'entrain land'gcarry outfrom the reactor, in

shite of the use of a disengaging space 30, particles of a size, theentrainment of which it is desirable to prevent. Furthermore, thiscondition becomes worse'the'larger the diameter of the vessel 15 used."Consequently, it has been found necessary to insertnearthe top of thedisengaging space'BB andnear'the outlet pipes 2 and-22 therefrom andbetween said outlet pipes-and the topsof the jumper pipes23v and/or thesurface of thecon tact materialbedlfia bafilesuch as plate 18 in whichare drilled a number 'of'holes uniformly spaced and distributed and ofsuch size as to cause a pressure drop 'due to the passage of theeflluentvaporstherethrough which pressure drop may be very-low or which'may beconsiderablebut which must ibeisubstantially greater than the pressuredrop due to "the ,flowof 'the'effluent vapors between the outlet of saidholes 'inthe baiile plate and the vapor outlet pipes 2 and '22. Due tothis pressure drop through :the orifice holes'20in ithe bailleplate 1'8,the tendency of direct vapor flow between the .tqpsof jumperpipes 23and/or the surface of the bed lfiand the outletpipesll and 22 iscounteracted; and, since .the holes in any section of the plate I8varedistributed so as to present ,anprifice ,area whichis directlyproportional to the-area of the cross. section-of ,thedis engaging spacecovered ,by vthatsection of the plate, the vapor flows .up through thedisengagin space up to'the plate t8v asan essentially single uniformzone of vflowextending across the entire disengaging space ,cross,section .thereby substantially preventin .cntrainmentfrom saiddisengaging space of contact material particles larger or equal to thatminimum size which ,itis desirable to retaininthispart otthecyc'licsystem.

Notonly are variousrnodifications of orifice hole size, shape and. arangement possible within this invention, as above shown, but alsovariousrnodifications of the baflle are possible. For example, Figure 4is .a view looking upwardly'at a pipe manifold arrangement ,consisting.of a pipe 3, i 32 passing across and extending out through two sides ofva disengagingspace '30 of square cross section, to which pipe withinthe disenga ing space areperpen'dicularly connected 9. numberofuniformly.spaced'branched pipes 3d throughBB inelusive, which extendacross-thec'ross sectional? the disengaging space. Along lines about 20oh the vertical plane through these pipes. (3!,32 and 34-39 inclusive).on the lower sides thereof are drilled anumber of .uniformlyspacedslots ,33,

all of which form ansorificepattern distributed tuni'forrnlywith respectto the square disengaging spacej30. zftlsoextending down into thisdisengagins-snaceiam i iqu n acumateriai e dp pes 25-291nclusive."*InFigurefi We find an'elevation' view, partially in section of thisinstallation in which I5 is the shell of the disengaging space and 26and 29 are two of the contact material feed pipes through which thecontact material charges to bed H5 at the bottom of the disengagingspace 30. The contact material in the bed I6 flows continuously downinto a reaction zone below, not shown. Also we find the pipes 3|, 32,34, 35 and. 36 extend across the disengaging space near the top. In thisarrangement all the effluent vapors pass up through the surface of thecontact material bed I 6 and up through the disengagin space 3|! andthen through the slots 33 into the pipes 3|, 32, 34, 35 and 36 and also31, 38 and 39 shown in Figure 4, and finally out through pipes 3| and32. Obviously the greater the number of pipes used in such anarrangement, the more uniform will be the vapor flow up through thedisengaging space 30. Although slots 33 are shown in this arrangement,the use of holes or apertures of any other shape is not precludedprovided that they are properly distributed and that the pressure dropdue to vapor flow therethrough is of the proper magnitude. Also theslots or holes might be placed on the upper side of the pipes ratherthan on the lower side and from this it can be seen that although thebaffle and orifices, which in this instance are the walls of the pipesand the slots therein, must be between the bottom of the disengagingspace and the outlet therefrom in the line of vapor flow, they need notnecessarily be therebetween from an elevational standpoint.

Still another type of baflle and orifice arrangement is shown in Figure6 in which I 5 is the shell of the disengaging space, I! is the contactmaterial feed pipe through which contact material flows to bed I6 at thebottom of the disengaging space and then down into the reaction zone,and 2| and 22 are vapor outlet pipes on two opposite sides of thedisengaging space. Just below the outlet pipes 2| and 22 are the twointerlocking rows of baffle plates 43 and 44 each row consisting of anumber of uniformly spaced flats the long sides of which are set at anangle with the horizontal preferably not less than 35, which flatsextend entirely across the disengaging space and are supported by theshell thereof on their two extreme ends by some suitable means not shownherein. The interlocking bafile arrangement thus obtained entirelycloses ofi the cross section of the disengaging space except for thesmall apertures left between the nearly touching edges of theinterlocking rows of plates or slats, which apertures extend along theentire length of the slats and across the entire width of thedisengaging space cross section. By the uniform and proper spacing ofthe slats these apertures may be made to automatically constitute apattern of uniformly spaced and distributed orifices for vapor passage,of such size and area as to cause the desired pressure drop on thepassage of the effluent vapors therethrough,

Thus far the application of this invention has been shown only toreactors or vessels through which a substantially continuous column ofdownward moving particle form material continuously flowscountercurrently to the flow of reactant vapors which are ultimatelywithdrawn from the top of the reaction zone. The invention may equallywell be applied to reactors or vessels in which the contact materialflows down through the reaction zone concurrently with the flow ofreactant vapors, which are subsequently removed through a disengagingspace below the said reaction zone. Such an arrangement is shown inFigure 7 in which I4 is the .confining shell of the lower part of thereaction zone and pipes 40" are large drain pipes therefrom down throughwhich the reactant vapors and contact material flow to the bed 4| at thebottom of the disengaging space 30. The vapor disengages from thecontact material at the ends of the pipes 48 and at the surface of thebed 4| and passes up through space 30 and through the orifices 20 in theplate baffle |8 and then out through the outlet pipe 2|.

Still another type reactor for which this invention may be used is shownin Figure 8 in which particle form contact material of relatively smallsize is charged through pipe l'l onto a conical shaped distributingbaffle 47 supported from the shell M of the reactor by members 48. Thecontact material then slowly falls through the reaction zone as a denserain countercurrent to a reactant vapor passing up therethrough at avelocity slightly less than that required to float and carry along thecontact material. The vapor then passes up out of the reaction zone andthrough the disengaging space 30 and up through the orifices 2|) in thebaffle plate l8 and finally out through outlet pipe 2|. In this instancethe baflle plate and orifices not only serve to force auniform flow ofvapor up through the entire cross section of the disengaging space 30thereby pre venting entrainment of contact material out with theeflluent vapors but also serve the very important function of forcingthe flow of the reactant vapors up through the entire cross section ofthe reaction zone itself to be uniform. This is here possible becausethe pressure drop due to the flow of reactant vapors up through theunbafiled reaction zone of this type of reactor is very low and theuniformity of vapor flow would be greatly influenced by a localizedvapor outlet passage such as pipe 2| unless the effect of this localizedoutlet connection is counteracted by the uniformly distributed orificesof the baffle arrangement of this invention.

In all the above described modified forms and applications of thisinvention the same broad principles and functions are involved, namely,the provision at or near the effective top of the vaporsolid disengagingspace of a reactor or regeneration vessel through which a particle formsolid contact material continuously flows in contact with a reactantvapor, of a bafile and orifice arrangment located so as to be in thepath of vapor flow between the bottom of said disengaging space and thevapor outlet passage near the top of the disengaging vessel, in whichbafille and orifice arrangement the orifices are uniformly spaced anddistributed so as to present at any horizontal cross section of thedisengaging space a total orifice area proportioned to the area of thatsection of the disengaging space and in which baffle and orificesarrangement the orifices are of such size, shape and area as to cause apressure drop due to the flow of efiluent vapors therethrough which issubstantially greater than the pressure drop due to the flow of saidefiluent vapors between the outlet of said orifice bafile arrangementand the vapor outlet pipes from the disengaging Vessel, the said baffleand orifice arrangement thereby effectively counteracting the disturbinginfluence of localized vapor outlet pipes, on the uniform flow ofefiluent vapors up through the entire cross section of the disengagingspace.

Since the desirable pressure drop through-the baille-orifice arrangementof this invention is 'dee pendent upon many variables inherent in thespecific cyclic operation to whichit is applied,

7 aszthe size-and density of the partic'lemiorm contact.-materia-l,.thenature and properties of the: reactant vapors, the total pressure andthe temperature on the system and the pressure drop to the flow ofeiiluent vapors between the outlet of the orifice-bafile' arrangementandthe disengaging vessel vaporoutlet pipes, it is ob:- viously impossibleto" set any definite fixed dimensions or size for the orifices orslatsin the baflle arrangements of this invention. Once-the variables areknown and once it is decided which type-of: the various modified formsofthiss inventiQIlwiS best adapted for the specific application, it-Jispossible to calculate the number and size ofs-the orifices and slatsnecessaryto cause the requi -red pressured drop. It is important, ofcourse, that the slats or orifices be distributed uniformly across theentire disengaging space crosssecti'on and-that the area of suchslats-in every section be proportional tothe area of the disengagingspace controlled by them. The pressure drop through the baffle-orificearrangement may in some low pressure applications be as low as 1 or 2inches of water and in other installations the upper range of thepressure drop across the said arrangement may be limited o-nlybypractical considerations;

Furthermore, since the vapor flow in that part oi the disengaging vesselbetween the bafileorifice arrangement and the vapor outlet pipes fromthe vessel will obviously not be uniformly distributed, it is practicalto position the baflleorifice arrangement as near as'possible to: thetop of the disengaging space,

It should be-understood that the details of construction and arrangementand the systems shownto which this invention may be applied are; merelydiagrammatic and exemplaryin charactor and it is not intended that thisinvention be limited to the particular details shown or't'o theparticular types of reaction vessels or systems herein described.

We claim:

1. In a reactor whereinsgasiform hydrocarbons are contacted with adownwardly moving column ofparticle-form' solid contact mass material, asubstantially vertical reactor vessel having a substantially constanthorizontal cross-sectional area along a major'portion' of its verticallength, conduitrmeans adapted for substantially continuous introductionofcontact material into said reactor extending downwardly into saidreactor and extendingzverti-cal'ly" within said reactor a. substantialdistance within said major portion ofthe reactor length wherein thehorizontal cross-sectional area is substantially constant, therebyproviding within the upper section of said reactor above the-lowerextremity of said conduit means a subs-tantially vertical straight gasdisengaging space having a cross-sectional area for gas flow alon-g itsentire length substantially equal to the total cross-sectional area ofthat portion of said reactor which is below the lower extremity of saidconduit means and which is occupied by a substantially compact column ofsaid contact material, an outlet for hydrocarbons spaced substantiallyabove the lower extremity of said conduit means, and between the levelof said outlet and said disengaging space baflle means across saidreactor defining the upper extremity ofsaid' disengagingspace andadapted to-provide a plurality oi -apertures substantially uniformlydistributed with respect to the cross-sectional area of the reactor,said apertures having atot'al gas passage area suficiently restricted tocause a substantial pressurez difierential; between said disengagingspace and said outlet.

2.. In an apparatuswherein hydrocarbons are contacted ;with a:substantially compact column-of downwardly moving particleeiorm solidcontact mass material; a. vessel-adaptedfor confiningsaid solid materialas asubstantially compact column of downwardly movingl'particles andforpassage of said hydrocarbons through: said column,. at least one feedconduit for solid material feed extending downwardly" into said vesseltoalevel a-substantial distancexbelow the upper end; of said vesselthereby defining agas-solid disengaging. space within: the .uppersectionof said vessel, an outlet for saidhydrocarbons near the. upper endofsaid vesseLrbafile-means across said vessel at a level shortlybelowsaid: hydrocarbon outletand substantially above the lower end of saidsolid feedconduit said bafliemeans defining, the upper extremity of saiddisengaging space and said=baiiie means being adapted to provide'aplurality of apertures forgas flow substantially uniformly distributedacross the cross-section of said disengaging space, said apertureshaving-- a total gaspassage area sufficiently restricted to cause asubstantial'pressure differential between said disengaging space andsaid outlet.

3. The apparatusof claimz2 in-which the bafiie means is a partitionplate extending entirely across thereactorgand provided with a pluralityof relativelysmall orifices distributed substantially uniformlyover'itssurface.

'4. The apparatus of" claim 2 in which the baffle means is a branchedpipe manifold extending fromsaid outlet in such manner that orifices insaid pipe manifold are substantially uniformly distributed with respectto section. I

5. The apparatus-of cla 'm 2-in-which the bafile means is composed of ahorizontal assembly of sloped flats extending from side to side of thereactor, the slats therebetween forming the orifices.

6. In an apparatus'wherein hydrocarbons are contacted with" a downwardlymoving substantially compact mass of, particle form contact materia-Lavessel of substantially constant crosssectional area along its verticallengthadapted forconfining-saidsolid material as a substantially compactcolumn and for passage of' said hydrocarbons through saidcolumn, atleast one feed conduit for solid material feed extending down- Wardlyinto said vessel to a level a substantial distance' below" the upperend=ofsaid vesselthereby defining a gas-solid disengaging space withinthe upper sectionof said vessel, an outlet for said hydrocarbons nearthe upper end of said vessel, saiddisengaging space being substantiallystraight and vertical and freeof 'baflies, a partition across said,vessel at a level shortly below said hydrocarbon outlet. andsubstantially above the lower end of said solid feed conduit-and withinthat portion of the vessel length wherein its crosssectional area issubstantially constant, said partition defining the top of said:disengaging space; a plurality of apertures in saidpartition uniformlydistributed across it'sarea, said apertures being of substantial sizebut being sufficiently restricted in totalgas: passage area to cause asubstantial pressure difierential between said disengaging-space andsaid hydrocarbon outlet.

- r ERNEST UTTERBAGK.

EDWARD L. SINCLAIR. JOHN A. GRGWLEY, .JRT.

(References on following page) the reactor cross- 9 REFERENCES CITEDNumber The following references are of record in the file of thlspatent. 2:367:281

UNITED STATES PATENTS 5 Number Name Date N b 1,845,058 Pier Feb. 16,1932 g g 2,231,424 Huppke Feb. 11, 1941 2,259,487 Payne Oct. 21, 1941Name Date Sheppard May 2, 1944 Hemminger Oct. 3, 1944 Johnson Jan. 16,1945 FOREIGN PATENTS Country Date Great Britain Mar 16, 1942 Certificateof Correction Patent No. 2,457,098. December 21, 1948. ERNEST UTTERBAOKET AL.

It is hereby certified that error appears in the printed specificationof the above numbered patent requiring correction as follows:

Column 3, line 70, for the word seated read stated;

and that the said Letters Patent should be read with this correctiontherein that the same may conform to the record of the case in thePatent Office.

Signed and sealed this 31st day of May, A. D. 1949.

THOMAS F. MURPHY 3 Assistant Commissioner of Patents.

